Siemens Gas and Power Overview of additive manufacturing, benefits and … · SST-300 industrial steam turbine Challenges Adaption of the components to customers challenging environment

Confidential © Siemens Energy, 2020Siemens Energy is a registered trademark licensed by Siemens AG.

Siemens Gas and PowerOverview of additive manufacturing, benefits and challenges

industrial approach for AM

Pajazit Avdovic PhD, Senor Key Expert AM

Additive manufacturing in nuclear energy applications

2020-09-23

Pajazit Avdovic | SE GP I SV TI AM ID

Confidential © Siemens Energy, 2020

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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.

Siemens Gas and Power

Turbine manufacturing in Finspong since 1913

Part of Siemens since 2003

2020 Siemens Energy AB

approx. 2,600 in Finspong & 100 in Trollhattan

Since the start in 1913, we have sold 1000 gas turbines, ~ 2,300 steam turbines and ~ 50 power plants

95% is exported and in more than 100 countries there 90% with service agreements



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Additive Manufacturing at Siemens Energy AB



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Gas turbines with it’s complex parts in expensive material

and

relatively small volumes makes AM very attractive!




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2019

SGT-800

Heat shield

2018

SGT-700

Burners

Commercial

operationOu

tco

mes

Key e

nab

lers

FY

SLM: Selective Laser Melting

From R&D to serial parts production with SLM technology in 10 years

2006

Material

Solutions

founded in

the UK

First

Selective

Laser Melting

demonstrators

2012

Installation

of 1st EOS M280

SLM machine in

FSP, specifically

adapted for Burner

repair

2013

First

SGT-800

Rapid Burner

Tip Repair

SGT-750

combustion

swirlers in

commercial

operation

2014

Dedicated

Additive CoCs

established

Develop-

ment and

qualification of

Processes and

Materials

2017

Turbine

blade printed

& tested

in engine

(SGT-100)

2009

Installation

of the 1st EOS

M270 SLM

machine in

FSP

2015

Prototyping

of qualification

parts for LGT,

IGT, AGT, IST

First

M400/4

Installed New M400/4

Shared

modules

Installed

New workshop

…

Blades

Vanes

Ring Segment

SGT-1000F

Burner head in

commercial

operation

2016

Acquisition

Finspong

Industrial

workshop

inaugurated

Siemens was an early adopter of SLM AM technology and have successfully scaled its production



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Siemens Gas and Power is one of the world leaders in designing and producing commercial AM components for serial production

Siemens Gas

and Power’s

experience

covers today

more than…

40+3D printing machines operational worldwide

Over

10 years

experience of SLM

20+components already

commercially implemented

>1 500 000operating hours on Siemens turbines

150+specialized engineers

200components identified

for AM until 2025

Energy AutomotiveAerospace Tooling & processing

3rd party

business



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Why Siemens Gas and Power works with Additive manufacturing

• Fast technology validation &

product development on demand

• Shortened process development

• Overall lead time reduction

• Mitigate single source situations

on e.g. mature parts

• Reduction of assemblies to one

component

• Small batch sizes & different

parts in one build job

• Reduced emissions through

improved fluid mixing, e.g.

complex nozzle designs

• Reduced waste from alloys

• New geometries

• Better heat transfer & cooling

• Improved efficiency & power

output

Innovative

Designs

Environment

Benefits

Supply Chain

& Reduced

Complexity

Time-to-Market

& Lead Time

Reduction

75%Reduction of

development time

65%Less resources

in production process

30%Reduction of greenhouse

gas emissions*Flexibility for

design of parts



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What benefits are enabled by Additive manufacturing for the customers?

• Possibility to store parts digitally

in databases –as Digital Twins -

instead of a physical storage

• Sourced parts on demand

located near the source of need

• Minimum order quantities since

AM allows for economical

production in small units

• Minimizing inventory costs for

working capital, warehousing,

and obsolescence

• Possibility to order obsolete part

through AM reversed

engineering (in consideration with

IP rights) instead of keeping the

parts on stock

• Reduced company carbon

footprint through e.g. less material

waste and reduced transportation

of parts

• Improved design for better

efficiency & power output

Environment

Benefits

Supply Chain

benefits

Spare parts

on demand

90%Reduction of

lead time

60%Faster

repairs

Obsolescence

management

Possibility to manufacture

obsolete parts

Reducing

CO2 emissions



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Our Unique Selling Propositions – Outstanding in the field of metal Additive manufacturing

Aim at highest quality

Test and implementation

according to highest standards

(AS 9100, ISO 9001, Nadcap)

Unique capability

One of the market leader for most difficult high-temperature alloys and an extensive material database for most common nickel based alloys

Proven references

More than 1 500 000 operating hours in commercial operation and high performance parts in various industries

Complete service

Offers within complete value chain from consulting and training to manufacturing and post-processing



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Gas turbine focal areas for Additive Manufacturing today

Turbine

Small parts

Blades and Vanes

Combustion System

Burner / Swirler / Nozzle / Mixer

Compressor

Small parts



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Key factors and technologies in the development of future gas turbines

• Increase of mass flow

• Increase of pressure ratio

• 3D aerodynamics optimization

• Reduction of aerodynamic losses

Compressor Combustion

• Higher combustion temperatures

• Optimized burner (fuel flexibility)

• Reduced emission

• Increased efficiency

Turbine

• Higher turbine inlet temperatures

• New materials and coatings

• Improved cooling and sealings

• 3D aerodynamics, loss reduction

Additive manufacturing considerably reduces timeframes to reach goals



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Fields of use and application

Rapid Repair

▪ Product: SGT-700/800

▪ Component: Burner tip

▪ Benefit:

− 90% lead time reduction

▪ Status: In commercial

application since 2013

Spare parts on

demand

▪ Product: SGT-1000F

▪ Component: Burner head

▪ Benefit:

− Reduced lead time

by up to 40%

▪ Status: In commercial

application since 2016

Rapid Prototyping

▪ Product: SGT5-4000F

▪ Component: Turbine Vane

▪ Benefit:

− Development time

reduction by 75 %

− Early validation of

NextGen Designs

▪ Status: Tests ongoing

Rapid Manufacturing

▪ Product: SGT-700/800

▪ Component: Burner

▪ Benefit:

− Higher performance

− 85% lead time reduction

▪ Status: Final testing phase



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AM challenges and opportunities

Challenges• Material knowledge

• Design culture

• Stand-alone software

• Training

• Machine performance

• Quality issues

• Health and Safety concerns

Disappointment:

”It is not just 3D-Printing!

It is much more complex..”

2020+2009

Innovation triggerPeak of inflated

expectations

Plateau of

productivity

Slope of

enlightenment

Trough of

disillusionment

201820162015

Connected AM

Connected” through MES, AM Network, Digital Twin and Use Build Job

Simulation

Learning AM

“Learning” through Big Data Analytics, AM Monitor, Virtual

Storage and Machine Learning

Intelligent AM

“Intelligent” through Robots, VR/AR, AI

Autonomous AM 2025 +

IoT for AM

Traditional AM



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AM burner manufacturing for flexibility, shorter lead time and improved lifetime

Conventional

• 13 parts / 18 welds

• TBC on front

• 26w lead time

SLM burner

• 1 integrated part

• No TBC due

• 3w lead time

• Manufacturing of SGT-700 / 800

burners by means of SLM

• Redesign of existing burners for

SGT-700 / 800 to utilize the

design freedom offered by SLM

• Full scale engine test performed

• Commercial operation in 2018

Approach Benefits

• Reduced lead time by

23 weeks

• Enabling customization

for fuel flexibility

• Removal of TBC



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Our references – First 3D printed water pump impeller is successful commercial operation at nuclear power plant

Challenges

Obsolete part, since the original

supplier no longer existed

• Experts at Siemens Slovenia reverse

engineered the impeller to produce a

"digital twin" that served as the basis for

the 3D printing technique

• Assured qualification of part with high

safety and reliability requirements

Solution

• Possibility to re-produce an obsolete part

• Lead time reduction for parts replacement

• Saving of material

• Eliminated tools

• On demand

Customer

Benefits

Customer Nuclear Power Plant Krško

Country Slovenia Obsolete part

Reverse

engineering and

qualification of

high

requirements

Significant

lead time

reduction



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Our references – Two oil sealing rings installed as replacement parts in a SST-300 industrial steam turbine

Challenges

Adaption of the components to

customers challenging environment

and needs

• Siemens engineered, designed and developed

the part as part of a collaborative project between

Siemens experts in Germany, India and Sweden

• Optimized performance that could not have been

achieved only with traditional manufacturing

processSolution

• Specific changes with high impact in the design

leading to improved functioning of the oil sealing

ring

• Printed oil sealing ring in one single step

• Saving of material and reduced weight by

approximately 80 percent due to the use of

aluminum and the weight-optimized design

• Significantly reduced lead-time

Customer

Benefits

Challenging

environment and

need of the

customer

Optimized

performance by

Additive

manufacturing

Reducing weight

by Additive

Manufacturing

CustomerJSW Steel Ltd. plant in

Salem

Country India



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Our references – Titanium high pressure hydraulic manifold Maximum availability for passenger aircraft

Challenges

• Maximum availability and safety

requirements

• Light weight and long lasting design

• Proof of long-term functionality

• Combination of advanced Additive Manufacturing

technologies from a variety of business fields

• Unique design features technical requirements

• Optimized performance that can only be

manufactured using Additive Manufacturing

• Tested under extreme conditions (Max. 5,500 psi

/ 379 bar for 2,000,000 cycles)

Solution

• Fulfilling most demanding requirements by

Aerospace industry

• Highest availability for maximum passenger

safety

• Accelerated technology validation delivered by

expertized one-stop shop

Customer

Benefits

Most demanding

requirements by

Aerospace

industry

Innovative

design for

Additive

Manufacturing

Additive

Manufacturing in

high quality

materials

CustomerSumitomo Precision

Products Co., Ltd.

Country Japan



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Our references - Additively manufactured and tested gas turbine blade in Alloy 247, major breakthrough

Shortened lead time by

75%

3D-printing use case or application

Siemens awarded by ASME for

3D-printed gas turbine blades

Siemens, Superalloy gas turbine

blades – winner

Travels over

1,000 mphReduced costs by

70%

Surrounded by gas at

1,250 ºC

Improved efficiency by

0,1%



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• Reliable supply chain partner for

prototype and serial production of AM

components in adjacent industries

• Consulting, engineering and

manufacturing services tailored to

customer needs

• Leading user of metal AM

components for power generation

assets

• Dedicated research & development

budget

Energy AutomotiveAerospace Tooling & Processing

3rd party

business

Siemens Gas and Power – Additive Manufacturing Providing customer value through manufacturing and service



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Our Unique Selling Propositions – Proven references

Unique capabilityOne of the market leader for most difficult high-temperature alloys and an extensive material database for most common nickel based alloys

Six fully qualified AM

materials available in

Siemens design systems

More than 10 years

experience in high

temperature metal AM

Extensive materials

database

Materials & technology

roadmap in place

Experienced with difficult

to weld alloys

Dedicated research &

development budget



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Unique capabilityOne of the market leader for most difficult high-temperature alloys and an extensive material database for most common nickel based alloys

Qualified print process

Readily weldable

Nickel Superalloys

• Haynes 230

Aluminum

• A20X

Difficult to weld

Nickel Superalloys

• CM 247 LC

• In 738 LC

• C 1023

• MAR M002

Ferrous alloys

• SS 17-4

• SS 15-5

• SS 304

• SS 316L

• Duplex 2205

• Maraging Steel M300

Cobalt alloys

• CoCrMo

• MAR M509

Titanium alloys

• Ti6Al4V

Fully qualified with design data

Nickel Superalloys

• In 939

• Haynes 282

Cobalt alloys

• Merl 72

Nickel Superalloys

• Hastelloy X

• C 263

• In 625

• In 718

Our Unique Selling Propositions – Unique capability



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Aim at highest qualityTest and implementation

according to highest standards

(AS 9100, ISO 9001, Nadcap)

• AS9100: ISO 9001

• International AM committees; ASTM, ISO

AM, Oil & Gas, Maritime

• Ongoing roadmap e.g. AMS 7003, Nadcap

M&I & ISO 17025

• Nadcap AM

• Machine qualification

• Full product qualification (e.g. Siemens PPQ)

• Job/machine specific trials (full scaling, partial

scaling, feature trials)

• Large Gas Turbine components qualified less

than 10 weeks

One of the industry

leading within Quality

Assurance

Validation and

Qualification

Our Unique Selling Propositions – Aim at highest quality



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Metrology and scanning

Metrology, scanning and

digitization of your spare parts

Training

Training and consulting for

your projects by experts

Manufacturing

Manufacturing and post-

processing for prototypes and

small series production

Complete service

Engineering

Engineering and reengineering,

design optimization of parts for

additive manufacturing

Offers within complete value chain from consulting and training to manufacturing and post-processing

Our Unique Selling Propositions – Complete service



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One of the largest Metal AM Printer fleets in the world

EOS M400-1

EOS M400-4 &

EOS M400-4 Shared

Modules

• 4 laser

• 400x400x400 mm

▪ Ultrasonic Cleaning

▪ 5 Axis Machining

▪ Blasting

▪ EDM Cutting/Bandsaw

▪ 3D GOM Scanning

▪ CMM

▪ Heat treatment

▪ Brazing

▪ Flow testing

▪ Coating

EOS M280

• 1 laser

• 250x250x325 mmCustomized for repair –

printing on top of base material

EOS M270

• 1 laser

• 250x250x325 mm

EOS M290

• 1 laser

• 250x250x325 mm RenAM 500Q

Printers Post processing

+Siemens

Supplier-base

for complete

production of

parts

Additive Manufacturing Printers and Post Processing ability



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Leading user of AM Technology to internal and external customers

Leading user of Software & Automation solutions

• Digital end-2-end chain

with NX12

• AM Monitor

• Control systems

• IoT Cloud solutions (Part

Manufacturing Platform)

• Mindsphere, Teamcenter

• MES, SCADA

Software & automation

AM for new products• AM for GT hot gas path components

AM for maintenance, repair

& obsolete parts

AM for prototyping and R&D

AM for tooling

Siemens is leading the Industrialization of AM –as an END USER and SUPPLIER



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Process steps for metal Additive manufacturing

Reversed engineering

Customer

Design Technical

preparation

Additive

Manufacturing

Physical part supply

Virtual Part

Storage/Capacity

Existing component

with 3D model

Design for AM

Optimization

Existing component without 3D

model

Preparation for manufacturing process of part

Manufacturingof part

Supply of part



Supply of partDesign for AM

Pre-qualification process

Reversed Engineering

by 3D scanning*

Component Validation

Reversed Engineering

by 3D scanning*

Issue Analysis

Component Validation



Supply of partDesign for AM



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Siemens Energy and University cooperation in AM area

Digitalization

Robotics

Application

Processes

Material

Generic; Application; Advanced

Member:

▪ ARENA

▪ CAM2

▪ DMRC

▪ TTC

Cooperation with:

❖ Universities

❖ Research Institutes

❖ Companies >50

Participating

➢ more than 20 ongoing projects/year (Sweden)

➢ EU funded projects



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Lattice structure and Topology optimization-Integration with CAD geometry (Niclas Strömberg, Ph.D., Docent-Örebro University)

The projects as a result of cooperation with universities and research institutes

Material Development: microstructures of 316L

3D Visualisation of Powderbed images

Original captured image Cropped and processed Generated 3D volume



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FBG Infrared camera

0

Calculation model

0

0

Optical fiber based

on

Fiber Bragg Grating

(FBG) technology


Inspection of component by Using of CT



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Several aspects related to

AM automation

• Analyze and create directives

and guidelines for what and in

which situations AM

production should be

automated.

• Adapt the automation based on

the need, not the need based

on the automation of AM

• Automation level of AM, what

is the company's policy ?

Collaborative robots for cleaning of machines chamber



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Removing barriers to industrializing additive manufacturing

(Source: TechClarity, 2017)

60

%

of Companies believe 3D is the best technology to help competitiveness

52 of Companies are prototyping today using additive manufacturing

78 of Companies consider additive manufacturing during the concept plane

58

%

of power users say they are looking to additive manufacturing to

accelerate their product development.

90 of companies consider 3D printing a competitive advantage.

(Source: Sculpteo, 2017)



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How to succeed with 3D printing - Critical success factors

Some operations deleted

Some operations added

Material development

Health & Environment

Expensive machinery

Manufacturing time

Pre and post processing

Management's trust in the method

Funding

Designers think DFAM

Right detail to Additive Manufacturing

The right material



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3D printed parts are already in use at Nuclear Power Plant Krško, Slovenia

First 3D printed water pump impeller is successful

commercial operation at nuclear power plant

Customers benefits:

• Obsolete parts can be re-produced

• Significant lead time reduction

• Parts on demand



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Project nr 2 in area of NUC



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Thanks you for the attention!

Published by Siemens Energy

Pajazit Avdovic PhD

Innovation Manager at Additive Manufacturing

Slottsvagen 2-6

612 83 Finspång

Sweden

Phone: +46 (0) 122 81479

Fax: +46 (122) 88712

Mobile: +46 702 85 82 35

E-mail: [email protected]

siemens-energy.com

https://www.siemens-energy.com/

mailto:[email protected]

Documents

Siemens Gas and Power Overview of additive manufacturing, benefits and … · SST-300 industrial steam turbine Challenges Adaption of the components to customers challenging environment